Assembly Structure for Corrugated Packaging

ABSTRACT

This document describes an assembly structure for corrugated packaging. The assembly structure is made from a single flat piece of fiberboard, including a center panel, two partial side panels, and two tabbed side panels. The center panel forms the bottom (or top) of the packaging. Tabbed side panels form two sides of the packaging, and the partial side panels, combined with the tabs or the tabbed side panels form the other two sides. The assembly structure can be made from corrugated fiberboard. The flutes of the corrugated fiberboard run in a direction that causes, when the panels are folded, the flutes of the two tabbed side panels to be vertical, providing strength in the stacking direction. While the flutes in the partial panels are horizontal, when the tabs of the tabbed side panels are folded to mate with the partial side panels, the flutes of the tabs are also vertical.

BACKGROUND

Consumer electronics at the retail level are often packaged in rigid boxes that are manufactured from various paperboard products, including chipboard (also known as grayboard), boxboard, and folding boxboard. As these materials have come into common use, packaging manufacturers have developed automated high-speed manufacturing and assembly processes. In these processes, the chipboard can be cut into a shape, for example, a “plus sign” (+), that allows for simple folding to make a box. The folded box may then be taped at one or more seams to hold its shape. A wrapper, often made from paper, can then be glued to the box. These paperboard products, however, are relatively heavy, which can increase transportation costs throughout the supply chain. Further, the various tapes, glues, paper wraps, coatings, and films used to produce the finished rigid box can make recycling more difficult or more expensive.

SUMMARY

This document describes an assembly structure for corrugated packaging. The assembly structure is produced as a single flat piece of fiberboard cut into any of a variety of shapes, as described. The assembly structure also includes scoring or creasing that allow the assembly structure to be folded into its final shape (“uprighted”) using typical automated assembly equipment and processes, with few or no modifications to the equipment and processes. For example, the assembly structure may be made from corrugated fiberboard, which is typically manufactured as a fluted corrugated sheet between two liner layers. Because corrugated fiberboard has higher compression strength in the direction of the flutes, the described assembly structure has a shape and scoring that allow the assembly structure to be folded so that most of the fluting in the sides of the finished box is vertical.

The shape and scoring of the assembly structure allow, for example, corrugated fiberboard to be used in place of chipboard in automated box-assembly processes. This can reduce the weight of both raw materials and finished products, which can save fuel, lower overall shipping costs, and reduce carbon emissions. Additionally, the amount of tape used to hold the box for wrapping may be reduced because there are fewer seams that must be taped. Similarly, by using corrugated fiberboard, more-easily recycled glues can be used to attach the wrapper to the box. Thus, the assembly structure for corrugated packaging can be used to produce a high-quality rigid box that may be lighter, more-recyclable, and manufactured using less fuel than many other rigid boxes made with materials such as chipboard.

Aspects described below include a planar paperboard structure. The planar paperboard structure includes a center panel and a first partial side panel. The first partial side panel extends from a first side of the center panel and includes a first folding interface between the first partial side panel and the first side of the center panel, and is configured to fold at the first folding interface to be substantially perpendicular to the center panel. The first partial side panel also includes a first mating edge opposite the first folding interface. The planar paperboard structure also includes a second partial side panel that extends from a second side of the center panel that is opposite the first side of the center panel. The second partial side panel includes a second folding interface between the second partial side panel and the second side of the center panel and is configured to fold at the second folding interface to be substantially perpendicular to the center panel. The second partial side panel also includes a second mating edge opposite the second folding interface. The planar paperboard structure also includes a first tabbed side panel extending from a third side of the center panel. The first tabbed side panel includes a third folding interface between the first tabbed side panel and the third side of the center panel and is configured to fold at the third folding interface to be substantially perpendicular to the center panel. The first tabbed side panel also includes a first tab that includes a third mating edge and a fourth folding interface adjacent the first tabbed side panel. The first tab is configured to fold at the fourth folding interface to be substantially perpendicular to the first tabbed side panel and to be substantially coplanar with the first partial side panel when the first partial panel is folded so that the first mating edge and the third mating edge are adjacent. The first tabbed side panel additionally includes a second tab that includes a fourth mating edge and a fifth folding interface adjacent the first tabbed side panel. The second tab is configured to fold at the fifth folding interface to be substantially perpendicular to the first tabbed side panel and to be substantially coplanar with the second partial side panel when the second partial panel is folded so that the second mating edge and the fourth mating edge are adjacent. The planar paperboard structure additionally includes a second tabbed side panel extending from a fourth side of the center panel that is opposite the third side of the center panel. The second tabbed side panel includes a sixth folding interface between the second tabbed side panel and the fourth side of the center panel and is configured to fold at the sixth folding interface to be substantially perpendicular to the center panel. The second tabbed side panel also includes a third tab that includes a fifth mating edge and a seventh folding interface adjacent the second tabbed side panel. The third tab is configured to fold at the seventh folding interface to be substantially perpendicular to the second tabbed side panel and to be substantially coplanar with the first partial side panel when the first partial panel is folded so that the first mating edge and the fifth mating edge are adjacent. The second tabbed side panel additionally includes a fourth tab that includes a sixth mating edge and an eighth folding interface adjacent the second tabbed side panel. The fourth tab is configured to fold at the eighth folding interface to be substantially perpendicular to the second tabbed side panel and to be substantially coplanar with the second partial side panel when the second partial panel is folded so that the second mating edge and the sixth mating edge are adjacent.

Other aspects described below include a method for forming a rigid box. The method includes folding a planar paperboard structure. The planar paperboard structure includes a center panel and a first partial side panel that includes a first folding interface and a first mating edge. The planar paperboard structure additionally includes a second partial side panel that includes a second folding interface and a second mating edge. The planar paperboard structure also includes a first tabbed side panel. The first tabbed side panel includes a third folding interface, a first tab with a third mating edge and fourth folding interface, and a second tab with a fourth mating edge and a fifth folding interface.

The planar paperboard structure also includes a second tabbed side panel. The second tabbed side panel includes a sixth folding interface, a third tab with a fifth mating edge and a seventh folding interface, and a fourth tab with a sixth mating edge and an eighth folding interface. The folding operations include folding the first partial side panel at the first folding interface to be substantially perpendicular to the center panel and folding the second partial side panel at the second folding interface to be substantially perpendicular to the center panel. The folding operations also include folding the first tabbed side panel at the third folding interface to be substantially perpendicular to the center panel and folding the second tabbed side panel at the sixth folding interface to be substantially perpendicular to the center panel. The folding operations further include folding the first tab at the fourth folding interface to be substantially perpendicular to the first tabbed side panel and substantially coplanar with the first partial side panel. The folding operations also include folding the second tab at the fifth folding interface to be substantially perpendicular to the first tabbed side panel and substantially coplanar with the second partial side panel. The folding operations additionally include folding the third tab at the seventh folding interface to be substantially perpendicular to the second tabbed side panel and substantially coplanar with the first partial side panel. Additionally, the folding operations include folding the fourth tab at the eighth folding interface to be substantially perpendicular to the second tabbed side panel and substantially coplanar with the second partial side panel. The method also includes applying tape to a first side interface that includes the first mating edge, the third mating edge, and the fifth mating edge. The taping is effective to cause the first partial side panel, the first tab, and the third tab to remain coplanar. The method also includes applying tape to a second side interface that includes the second mating edge, the fourth mating edge, and the sixth mating edge. The taping is effective to cause the second partial side panel, the second tab, and the fourth tab to remain coplanar. The method additionally includes applying glue to a wrapper configured to conform to an exterior surface of the folded planar paperboard structure. The method also includes attaching the wrapper to the exterior surface of the folded planar paperboard structure.

This summary is provided to introduce simplified concepts concerning the assembly structure for corrugated packaging, which are further described below in the Detailed Description. This summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in determining the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

The details of one or more aspects of an assembly structure for corrugated packaging are described in this document with reference to the following drawings. The same numbers are used throughout the drawings to reference like features and components:

FIG. 1 illustrates an example implementation of an assembly structure for corrugated packaging, including a planar paperboard structure.

FIG. 2 illustrates a perspective view of an example implementation of the planar paperboard structure of FIG. 1.

FIG. 3 illustrates a perspective view of an example implementation of the planar paperboard structure of FIG. 1, partially folded.

FIG. 4 illustrates a perspective view of an example implementation of the planar paperboard structure of FIG. 1 with the folding complete.

FIG. 5 illustrates example implementations of the planar paperboard structure of FIGS. 1-4, with different configurations of a first side interface and a second side interface.

FIG. 6 depicts an example method 600, which enables manufacturing an assembly structure for corrugated packaging.

DETAILED DESCRIPTION

Overview

This document describes an assembly structure for corrugated packaging. The assembly structure is made from a single flat piece of fiberboard with five sections, or panels, including a center panel, two partial side panels, and two tabbed side panels. The center panel forms the bottom (or top) of the box and is defined by four creases, which create folding interfaces. The partial side panels extend from two opposite sides of the center panel, and the tabbed side panels extend from two other opposite sides of the center panel. The tabbed side panels extend farther than the partial side panels, and each tabbed side panel includes two tabs at opposite ends of the tabbed side panels. The tabs are defined by additional creases and folding interfaces.

The partial side panels and tabbed side panels fold in the same direction to be roughly perpendicular to the center panel. The partial side panels are shorter than the tabbed side panels, which allows the four tabs to be folded toward the partial side panels. The external mating edge of the partial side panels and the internal mating edges of the tabs are designed so that when the assembly structure is folded and the mating edges of the partial side panels and the mating edges of the tabs are adjacent, all four side panels are of equal length.

Consider an example rigid box that can be made using the described assembly structure for corrugated packaging. In this example, the assembly structure is made from single-wall corrugated fiberboard, which is typically manufactured as fluted corrugated sheets (sometimes referred to as a corrugated medium) between flat liner layers. Single-wall (3-ply) corrugated fiberboard has one corrugated sheet between two liner layers. Other materials may also be used, including double-wall (5-ply) corrugated fiberboard, which has two corrugated sheets separated by one liner layer and with two exterior liner layers, boxboard, containerboard, and so forth.

The flutes of the corrugated sheet form column-like structures between the liners, increasing its compression strength in the direction of the flutes. Accordingly, the tabbed side panels of the assembly structure for the example rigid box extend from the center panel in a direction parallel to the flutes, and the partial side panels extend from the center panel in a direction perpendicular to the flutes. When the four panels are folded, the flutes of the two tabbed side panels will be vertical, providing strength in the stacking direction. While the flutes in the partial panels will be horizontal, when the tabs are folded to mate with the partial side panels, the flutes of the tabs are also vertical. This produces a box with at least some vertical fluting on all four side panels and with the entire perimeter of the open box having vertical fluting. Tape can then be applied to the seams formed by the mating edges of the partial side panels and the tabs, and a wrapper can be glued to the exterior of the box to hold it together. Various options are available for a cover or lid, including a sliding sleeve, like a matchbox, or shallow cap.

In another example, a telescoping two-piece rigid box can be made using the described assembly structure for corrugated packaging. A first piece can be a box made in a manner similar to the previous example. A second piece that is slightly larger can be made in the same manner. The second piece can slide down over the opening of the first piece to provide a cover or lid. The example telescoping box has additional strength compared to the previous example, because the bottom perimeter, provided by the second piece, and the top perimeter, provided by the first piece, have vertical fluting.

Both example rigid boxes can be assembled on existing automated assembly equipment. The assembly structure can be mechanically die-cut, scored (creased), folded, taped, and wrapped in the automated assembly equipment with few or no modifications. For example, additional or different plungers, folding bars, and/or rollers may be necessary in some cases to fold the tabs. In some implementations, cut-creasing (e.g., slitting or slotting) may be used in place of some or all of the creasing.

These are but a few examples of how the described techniques and devices may be used to produce the assembly structure for corrugated packaging. Other examples and implementations are described throughout this document. The document now turns to example apparatuses, processes, and techniques.

Example Apparatus

FIG. 1 illustrates an example implementation 100 of an assembly structure for corrugated packaging. As illustrated, the example implementation 100 is a planar paperboard structure 102 that includes a center panel 104, a first partial side panel 106, a second partial side panel 108, a first tabbed side panel 110, and a second tabbed side panel 112. The planar paperboard structure 102 can be made from any of a variety of materials. For example, planar paperboard structure 102 can be made from corrugated fiberboard, boxboard, containerboard, other fiberboard materials, or plastic materials (e.g., corrugated plastic sheeting). When made from corrugated fiberboard, the planar paperboard structure 102 can be made from corrugated fiberboard that includes fluting, or flutes, 114. The fluting 114 can have a variety of fluting grades (e.g., F-flute, E-flute, C-flute, or B-flute) and bursting strengths (e.g., Mullen Burst Test ratings of 125#, 200#, 275#, or 350#). The fluting runs parallel to the sides of the center panel 104 from which the first partial side panel 106 and the second partial side panel 108 extend, as described herein. A side view 100-1 of the planar paperboard structure 102 shows additional details of how the fluting 114 is oriented.

The center panel 104 can be made in a variety of shapes, including rectangular, square, circular, or ellipsoid. The first partial side panel 106 and the second partial side panel 108 can be any of a variety of shapes, including trapezoidal, rectangular, semi-circular, or semi-ellipsoid. Accordingly, the first tabbed side panel 110 and the second tabbed side panel 112 can also be made in a variety of shapes similar to those described with respect to the first partial side panel 106 and the second partial side panel 108. Example shapes for the partial side panels and the tabbed side panels are illustrated and described in other parts of this document.

The first partial side panel 106 extends from a first side of the center panel 104 and includes a first folding interface 116 between the first partial side panel 106 and the first side of the center panel 104. The first partial side panel 106 can fold at the first folding interface 116 so that it is substantially perpendicular to the center panel 104. The first partial side panel 106 also includes a first mating edge 118 on the side of the first partial side panel 106 that is opposite the first folding interface 116.

Similarly, the second partial side panel 108 extends from a second side of the center panel 104, which is opposite the first side of the center panel 104. The second partial side panel 108 includes a second folding interface 120 between the second partial side panel 108 and the second side of the center panel 104. The second partial side panel 108 can fold at the second folding interface 120 so that it is substantially perpendicular to the center panel 104. The second partial side panel 108 also includes a second mating edge 122 on the side of the second partial side panel 108 that is opposite the second folding interface 120.

The first tabbed side panel 110 extends from a third side of the center panel 104 and includes a third folding interface 124 between the first tabbed side panel 110 and the third side of the center panel 104. The first tabbed side panel 110 can fold at the third folding interface 124 so that it is substantially perpendicular to the center panel 104. The first tabbed side panel 110 also includes a first tab 126 and a second tab 128.

The first tab 126 includes a third mating edge 130 and a fourth folding interface 132 that is adjacent the first tabbed side panel 110. The first tab 126 can fold at the fourth folding interface 132 so that it is substantially perpendicular to the first tabbed side panel 110. Further, when the first partial side panel 106 is folded so that the first mating edge 118 and the third mating edge 130 are adjacent, the first tab 126 is substantially coplanar with the first partial side panel 106.

The second tab 128 includes a fourth mating edge 134 and a fifth folding interface 136 that is adjacent the first tabbed side panel 110. The second tab 128 can fold at the fifth folding interface 136 so that it is substantially perpendicular to the first tabbed side panel 110. Further, when the second partial side panel 108 is folded so that the second mating edge 122 and the fourth mating edge 134 are adjacent, the second tab 128 is substantially coplanar with the second partial side panel 108.

Similarly, the second tabbed side panel 112 extends from a fourth side of the center panel 104, which is opposite the third side of the center panel 104. The second tabbed side panel 112 includes a sixth folding interface 138 between the second tabbed side panel 112 and the fourth side of the center panel 104. The second tabbed side panel 112 can fold at the sixth folding interface 138 so that it is substantially perpendicular to the center panel 104. The second tabbed side panel 112 also includes a third tab 140 and a fourth tab 142.

The third tab 140 includes a fifth mating edge 144 and a seventh folding interface 146 that is adjacent the second tabbed side panel 112. The third tab 140 can fold at the seventh folding interface 146 so that it is substantially perpendicular to the second tabbed side panel 112. Further, when the first partial side panel 106 is folded so that the first mating edge 118 and the fifth mating edge 144 are adjacent, the third tab 140 is substantially coplanar with the first partial side panel 106.

The fourth tab 142 includes a sixth mating edge 148 and an eighth folding interface 150 that is adjacent the second tabbed side panel 112. The fourth tab 142 can fold at the eighth folding interface 150 so that it is substantially perpendicular to the second tabbed side panel 112. Further, when the second partial side panel 108 is folded so that the second mating edge 122 and the sixth mating edge 148 are adjacent, the fourth tab 142 is substantially coplanar with the second partial side panel 108.

In some implementations, the first partial side panel 106 and the second partial side panel 108 may extend from the center panel 104 (e.g., from the first folding interface 116 and the second folding interface 120, respectively) a distance that is no more than approximately forty-five percent of a length of the first tabbed side panel 110 measured from the third folding interface 124. In other implementations, the distance the first partial side panel 106 and the second partial side panel 108 extend from the center panel 104 can be another distance. For example, between approximately forty percent of a length of the first tabbed side panel 110 measured from the third folding interface 124 and approximately fifty percent of the length of the first tabbed side panel 110 measured from the third folding interface 124. In still other implementations, the distance the first partial side panel 106 and the second partial side panel 108 extend from the center panel 104 can be approximately forty-five percent of a length of the first tabbed side panel 110 measured from the third folding interface 124.

The size of the first partial side panel 106 and the second partial side panel 108 can also be determined based on a measurement of a combined area. For example, the area of the first partial side panel 106 may be defined as a fraction of the combined area of the first partial side panel 106, the first tab 126, and the third tab 140 (e.g., the area of the first partial side panel 106 may be no more than approximately fifty percent, between approximately forty percent and approximately fifty percent, or approximately fifty percent of the combined area). Similarly, the area of the second partial side panel 108 may be defined as a fraction of the combined area of the second partial side panel 108, the second tab 128, and the fourth tab 142 (e.g., the area of the second partial side panel 108 may be no more than approximately fifty percent, between approximately forty percent and approximately fifty percent, or approximately fifty percent of the combined area).

In some implementations, the planar paperboard structure 102 may be a single piece. The planar paperboard structure 102 may be die-cut from a larger piece (e.g., an exterior perimeter of the planar paperboard structure 102 is die-cut). Additionally, the first folding interface 116, the second folding interface 120, the third folding interface 124, the fourth folding interface 132, the fifth folding interface 136, the sixth folding interface 138, the seventh folding interface 146, and the eighth folding interface 150 may be creases, scores, cut-creases, slits, slots, or another type of folding mechanism. The folding interfaces may be different types of folding interface. For example, some may be creases, while others in the same planar paperboard structure 102 may be cut-creases.

The described planar paperboard structure 102 can be used to make a rigid box made from corrugated fiberboard, which can reduce weight and transportation costs and improve recyclability. At the same time, the corrugated fiber rigid box can be produced using automated assembly equipment with few modifications, or in some cases, no modifications to the automated assembly equipment. In this way, the customer can experience higher-end packaging that may be produced with lower transportation costs and carbon emissions than for similar rigid boxes made with other materials.

Example Techniques

FIG. 2, FIG. 3, and FIG. 4 illustrate how an example implementation of the planar paperboard structure 102 can be folded into a rigid box. FIG. 2 illustrates a perspective view 200 of an example implementation of the planar paperboard structure 102 prior to folding, similar to FIG. 1. A detail view 200-1 illustrates the orientation of the fluting 114 with respect to the planar paperboard structure 102. As shown by dashed lines 202, the fluting 114 runs in a direction parallel to the first edge of the center panel 104.

FIG. 3 illustrates a perspective view 300 of an example implementation of the planar paperboard structure 102 partially folded. The folding technique is depicting using arrows labeled 302 through 316. The arrows 302 and 304 show that the first partial side panel 106 is folded at the first folding interface 116 to be substantially perpendicular to the center panel 104 and that the second partial side panel 108 is folded at the second folding interface 120 to be substantially perpendicular to the center panel 104. Additionally, the first tabbed side panel 110 is folded at the third folding interface 124 to be substantially perpendicular to the center panel 104 and the second tabbed side panel 112 is folded at the sixth folding interface 138 to be substantially perpendicular to the center panel 104 as shown by arrows 306 and 308, respectively.

As shown by arrow 310, the first tab 126 is folded at the fourth folding interface 132 to be substantially perpendicular to the first tabbed side panel 110 and substantially coplanar with the first partial side panel 106. An arrow 312 shows that the second tab 128 is folded at the fifth folding interface 136 to be substantially perpendicular to the first tabbed side panel 110 and substantially coplanar with the second partial side panel 108. As shown by arrow 314, the third tab 140 is folded at the seventh folding interface 146 to be substantially perpendicular to the second tabbed side panel 112 and substantially coplanar with the first partial side panel 106. An arrow 316 shows that the fourth tab 142 is folded at the eighth folding interface 150 to be substantially perpendicular to the second tabbed side panel 112 and substantially coplanar with the second partial side panel 108.

Dashed lines 318 show how the fluting 114 runs in a direction parallel to the second edge of the center panel 104. When folded up, however, the fluting 114 of the first tab 126, the second tab 128, the third tab 140, and the fourth tab 142 runs perpendicular to the center panel 104. For example, a detail view 300-1 illustrates the orientation of the fluting 114 with respect to the second tab 128. In the detail view 300-1, additional dashed lines 320 demonstrate that the fluting 114 will be vertical when the second tab 128 is folded. In this way, when the planar paperboard structure 102 is folded, at least some of the fluting 114 will run perpendicular to the center panel 104 on every side of the planar paperboard structure 102, providing stacking strength.

FIG. 4 illustrates a perspective view 400 of an example implementation of the planar paperboard structure 102 with the folding complete. A detail view 400-1 shows that the fluting 114 (shown as dashed lines) will be vertical when the first tab 126 and the third tab 140 are folded. In this way, when the planar paperboard structure 102 is folded, at least some of the fluting 114 will run perpendicular to the center panel 104 on every side of the planar paperboard structure 102, providing stacking strength.

In some implementations, the folded planar paperboard structure 102 may be taped on one or both sides, as shown by a hatched area 402, to hold a first side interface (the hatched area 402 is not shown in the detail view 400-1). The first side interface includes the first mating edge 118, the third mating edge 130, and the fifth mating edge 144. The tape may be placed on one or both sides of the first side interface in order to cause the first partial side panel 106, the first tab 126, and the third tab 140 to remain coplanar. Similarly, a second side interface may be taped, as shown by another hatched area 404. The second side interface includes the second mating edge 122, the fourth mating edge 134, and the sixth mating edge 148. The second side interface may be taped on one or both sides to cause the second partial side panel 108, the second tab 128, and the fourth tab 142 to remain coplanar. Any of a variety of tape configurations may be used, including using one piece of tape on each side, a single piece of tape folded over, and so forth.

Additionally or alternatively, another planar paperboard structure (not shown) may be manufactured and folded to have an interior perimeter that is larger than an exterior perimeter of the planar paperboard structure 102, which enables the other planar paperboard structure to fit over the planar paperboard structure 102 in a telescoping configuration (e.g., to form a lid). In some implementations, the interior surface of the other planar paperboard structure is adjacent the exterior surface of the planar paperboard structure 102. For example, a clearance between the interior surface of the other planar paperboard structure and the exterior surface of the planar paperboard structure 102 may be two millimeters, one and one-half millimeters, one millimeter, or half a millimeter. In other implementations, a clearance between the interior surface of the other planar paperboard structure and the exterior surface of the planar paperboard structure 102 may be approximately zero millimeters, and the interior surface of the other planar paperboard structure and the exterior surface of the planar paperboard structure 102 touch each other, but they may slide against each other to allow the telescoping to function.

FIG. 5 illustrates example implementations 500-1, 500-2, and 500-3 of the planar paperboard structure 102 with different configurations of the first and second side interfaces. The example implementation 500-1 shows the first side interface as described with reference to FIG. 1 through FIG. 4. In this example, the first mating edge 118 is shaped like a partial trapezoid (e.g., the short parallel side and the two angled sides of a trapezoid). The third mating edge 130 and the fifth mating edge 144 are each obtuse angles that form part of a corresponding partial trapezoid. The three mating edges intersect to form the first side interface, which is made from the first partial side panel 106, the first tab 126, and the third tab 140. The second side interface, which includes the second mating edge 122, the fourth mating edge 134, and the sixth mating edge 148, may be manufactured in a same or different configuration.

In the example implementation 500-2, the first mating edge 118 is an arc. The third mating edge 130 and the fifth mating edge 144 each form part of another corresponding arc, which has a substantially same shape as the arc of the first mating edge 118. The second mating edge 122, the fourth mating edge 134, and the sixth mating edge 148, may be manufactured in a same or different configuration. For example, second mating edge 122 can be an arc, and the fourth mating edge 134 and the sixth mating edge 148 can each form another arc, which has a substantially same shape as the arc of the second mating edge 122.

In the example implementation 500-3, the first mating edge 118 is an obtuse angle. The third mating edge 130 and the fifth mating edge 144 each form part of another corresponding obtuse angle, which has a substantially same shape as the arc of the first mating edge 118. The second mating edge 122, the fourth mating edge 134, and the sixth mating edge 148, may be manufactured in a same or different configuration. In other implementations (not shown in FIG. 5), multiple other configurations, shapes, and/or arrangements of the first partial side panel 106, the first tab 126, and the third tab 140 (or the second partial side panel 108, the second tab 128, and the fourth tab 142) are possible.

Example Methods

FIG. 6 depicts an example method 600, which enables manufacturing an assembly structure for corrugated packaging. The method 600 is shown as a set of blocks that specify operations performed but are not necessarily limited to the order or combinations shown for performing the operations by the respective blocks. Further, any of one or more of the operations may be repeated, combined, reorganized, or linked to provide a wide array of additional and/or alternate methods. In portions of the following discussion, reference may be made to the example implementation 100 of the assembly structure for corrugated packaging of FIG. 1 or to the example implementation of the planar paperboard structure 102, as described in FIG. 1 through FIG. 5, reference to which is made only for purposes of example.

At 602, a planar paperboard structure is folded into a rigid box. The planar paperboard structure includes a center panel, a first partial side panel that includes a first folding interface and a first mating edge, and a second partial side panel that includes a second folding interface and a second mating edge. The planar paperboard structure also includes a first tabbed side panel, which includes a third folding interface, a first tab, and a second tab. The first tab includes a third mating edge and fourth folding interface. The second tab includes a fourth mating edge and a fifth folding interface. The planar paperboard structure further includes a second tabbed side panel, which includes a sixth folding interface, a third tab, and a fourth tab. The third tab includes a fifth mating edge and a seventh folding interface. The fourth tab includes a sixth mating edge and an eighth folding interface. The planar paperboard structure may be made from a variety of materials, including corrugated fiberboard. For example, the planar paperboard structure may be the planar paperboard structure 102, as described in any of FIG. 1 through FIG. 5.

Folding the planar paperboard structure into a rigid box involves multiple folding operations, which may be performed in a variety of sequences. For example, the multiple folding operations can begin with folding the first partial side panel at the first folding interface to be substantially perpendicular to the center panel, then folding the second partial side panel at the second folding interface to be substantially perpendicular to the center panel. The next folding operations can be folding the first tabbed side panel at the third folding interface to be substantially perpendicular to the center panel and folding the second tabbed side panel at the sixth folding interface to be substantially perpendicular to the center panel.

The folding operations can continue with folding the first tab at the fourth folding interface to be substantially perpendicular to the first tabbed side panel and substantially coplanar with the first partial side panel, and folding the second tab at the fifth folding interface to be substantially perpendicular to the first tabbed side panel and substantially coplanar with the second partial side panel. The last folding operations can be folding the third tab at the seventh folding interface to be substantially perpendicular to the second tabbed side panel and substantially coplanar with the first partial side panel, and folding the fourth tab at the eighth folding interface to be substantially perpendicular to the second tabbed side panel and substantially coplanar with the second partial side panel.

At 604, tape is applied to a first side interface of the planar paperboard structure. The first side interface can include the first mating edge, the third mating edge, and the fifth mating edge. Applying the tape can be effective to cause the first partial side panel, the first tab, and the third tab to remain coplanar. For example, the tape may be applied as described with reference to FIG. 4. In some implementations, the first side interface may be taped on only one side; in other implementations, tape may be applied on both sides. Any of a variety of tape configurations may be used, including using one piece of tape on each side or a single piece of tape folded over.

At 606, tape is applied to a second side interface of the planar paperboard structure. The second side interface can include the second mating edge, the fourth mating edge, and the sixth mating edge. Applying the tape can be effective to cause the second partial side panel, the second tab, and the fourth tab to remain coplanar. For example, the tape may be applied as described with reference to FIG. 4. In some implementations, the second side interface may be taped on only one side; in other implementations, tape may be applied on both sides. Any of a variety of tape configurations may be used, including using one piece of tape on each side or a single piece of tape folded over.

At 608, glue is applied to a wrapper, which is manufactured to conform to an exterior surface of the folded planar paperboard structure. For example, a paper wrapper can be cut into a shape similar to that of the planar paperboard structure 102.

At 610, the wrapper is attached to the exterior surface of the folded planar paperboard structure. For example, the paper wrapper described in operation 608 can be printed with graphics on one side, and the glue can be applied to the non-printed side so that when the wrapper is attached, the graphics are visible. In other examples, the wrapper does not include printed graphics.

In aspects, the method 600 may be used to assemble implementations illustrated in FIG. 1 through FIG. 5, or other implementations described herein, of the planar paperboard structure 102 using automated box-assembly equipment, such as a digital, mechatronic, or mechanical assembly machine manufactured by Emecci, SpA.

Some examples are provided below:

Example 1: A planar paperboard structure, comprising: a center panel; a first partial side panel extending from a first side of the center panel and including: a first folding interface between the first partial side panel and the first side of the center panel, the first partial side panel configured to fold at the first folding interface to be substantially perpendicular to the center panel; and a first mating edge opposite the first folding interface; a second partial side panel extending from a second side of the center panel that is opposite the first side of the center panel and including: a second folding interface between the second partial side panel and the second side of the center panel, the second partial side panel configured to fold at the second folding interface to be substantially perpendicular to the center panel; and a second mating edge opposite the second folding interface; a first tabbed side panel extending from a third side of the center panel, the first tabbed side panel including: a third folding interface between the first tabbed side panel and the third side of the center panel, the first tabbed side panel configured to fold at the third folding interface to be substantially perpendicular to the center panel; a first tab including: a third mating edge; and a fourth folding interface adjacent the first tabbed side panel, the first tab configured to fold at the fourth folding interface to be substantially perpendicular to the first tabbed side panel and to be substantially coplanar with the first partial side panel when the first partial panel is folded so that the first mating edge and the third mating edge are adjacent; and a second tab including: a fourth mating edge; and a fifth folding interface adjacent the first tabbed side panel, the second tab configured to fold at the fifth folding interface to be substantially perpendicular to the first tabbed side panel and to be substantially coplanar with the second partial side panel when the second partial panel is folded so that the second mating edge and the fourth mating edge are adjacent; a second tabbed side panel extending from a fourth side of the center panel, the fourth side of the center panel opposite the third side of the center panel, the second tabbed side panel including: a sixth folding interface between the second tabbed side panel and the fourth side of the center panel, the second tabbed side panel configured to fold at the sixth folding interface to be substantially perpendicular to the center panel; a third tab including: a fifth mating edge; and a seventh folding interface adjacent the second tabbed side panel, the third tab configured to fold at the seventh folding interface to be substantially perpendicular to the second tabbed side panel and to be substantially coplanar with the first partial side panel when the first partial panel is folded so that the first mating edge and the fifth mating edge are adjacent; and a fourth tab including: a sixth mating edge; and an eighth folding interface adjacent the second tabbed side panel, the fourth tab configured to fold at the eighth folding interface to be substantially perpendicular to the second tabbed side panel and to be substantially coplanar with the second partial side panel when the second partial panel is folded so that the second mating edge and the sixth mating edge are adjacent.

Example 2: The planar paperboard structure of example 1, wherein the planar paperboard structure is manufactured from corrugated fiberboard.

Example 3: The planar paperboard structure of example 2, wherein the corrugated fiberboard includes fluting, the fluting parallel to the first side of the center panel.

Example 4: The planar paperboard structure of example 3, wherein a fluting grade of the corrugated fiberboard is: F-flute; E-flute; C-flute; or B-flute.

Example 5: The planar paperboard structure of example 1, wherein: a distance the first partial side panel extends from the first folding interface is no more than approximately forty-five percent of a length of the first tabbed side panel measured from the third folding interface; and a distance the second partial side panel extends from the second folding interface is no more than approximately forty-five percent of a length of the first tabbed side panel measured from the third folding interface.

Example 6: The planar paperboard structure of example 1, wherein: a distance the first partial side panel extends from the first folding interface is between approximately forty percent of a length of the first tabbed side panel measured from the third folding interface and approximately fifty percent of the length of the first tabbed side panel measured from the third folding interface; and a distance the second partial side panel extends from the second folding interface is between approximately forty percent of a length of the first tabbed side panel measured from the third folding interface and approximately fifty percent of the length of the first tabbed side panel measured from the third folding interface.

Example 7: The planar paperboard structure of example 1, wherein: a distance the first partial side panel extends from the first folding interface is approximately forty-five percent of a length of the first tabbed side panel measured from the third folding interface; and a distance the second partial side panel extends from the second folding interface is approximately forty-five percent of a length of the first tabbed side panel measured from the third folding interface.

Example 8: The planar paperboard structure of example 1, wherein the first partial side panel and the second partial side panel are trapezoidal.

Example 9: The planar paperboard structure of example 1, wherein the first partial side panel and the second partial side panel are: rectangular; semi-circular; or semi-ellipsoid.

Example 10: The planar paperboard structure of example 1, wherein: the first mating edge includes a first arc; and the third mating edge and the fifth mating edge comprise a second arc, the second arc having a substantially same shape as the first arc.

Example 11: The planar paperboard structure of example 1, wherein: the second mating edge includes a third arc; and the fourth mating edge and the sixth mating edge comprise a fourth arc, the fourth arc having a substantially same shape as the third arc.

Example 12: The planar paperboard structure of example 1, wherein the center panel is rectangular.

Example 13: The planar paperboard structure of example 1, wherein the center panel is: square; circular; or ellipsoid.

Example 14: The planar paperboard structure of example 1, wherein the planar paperboard structure includes an exterior perimeter that is die-cut.

Example 15: The planar paperboard structure of example 1, wherein the first folding interface, the second folding interface, the third folding interface, the fourth folding interface, the fifth folding interface, the sixth folding interface, the seventh folding interface, and the eighth folding interface are creases or cut-creases.

Example 16: The planar paperboard structure of example 1, wherein the planar paperboard structure is a single piece.

Example 17: The planar paperboard structure of example 1, wherein: the first partial side panel is folded at the first folding interface to be substantially perpendicular to the center panel; the second partial side panel is folded at the second folding interface to be substantially perpendicular to the center panel; the first tabbed side panel is folded at the third folding interface to be substantially perpendicular to the center panel; the second tabbed side panel is folded at the sixth folding interface to be substantially perpendicular to the center panel; the first tab is folded at the fourth folding interface to be substantially perpendicular to the first tabbed side panel and substantially coplanar with the first partial side panel; the second tab is folded at the fifth folding interface to be substantially perpendicular to the first tabbed side panel and substantially coplanar with the second partial side panel; the third tab is folded at the seventh folding interface to be substantially perpendicular to the second tabbed side panel and substantially coplanar with the first partial side panel; the fourth tab is folded at the eighth folding interface to be substantially perpendicular to the second tabbed side panel and substantially coplanar with the second partial side panel; a first side interface that includes the first mating edge, the third mating edge, and the fifth mating edge, is taped on both sides, effective to cause the first partial side panel, the first tab, and the third tab to remain coplanar; a second side interface that includes the second mating edge, the fourth mating edge, and the sixth mating edge, is taped on both sides, effective to cause the second partial side panel, the second tab, and the fourth tab to remain coplanar; and further including another planar paperboard structure configured with an interior perimeter that is larger than an exterior perimeter of the planar paperboard structure, effective to enable the other planar paperboard structure to fit over the planar paperboard structure in a telescoping configuration wherein an interior surface of the other planar paperboard structure is adjacent an exterior surface of the planar paperboard structure.

Example 18: A method for forming a rigid box, comprising: folding a planar paperboard structure, the planar paperboard structure including: a center panel; a first partial side panel, the first partial side panel including a first folding interface and a first mating edge; a second partial side panel, the second partial side panel including a second folding interface and a second mating edge; a first tabbed side panel, the first tabbed side panel including a third folding interface, a first tab with a third mating edge and a fourth folding interface, and a second tab with a fourth mating edge and a fifth folding interface; a second tabbed side panel, the second tabbed side panel including a sixth folding interface, a third tab with a fifth mating edge and a seventh folding interface, and a fourth tab with a sixth mating edge and an eighth folding interface, the folding comprising: folding the first partial side panel at the first folding interface to be substantially perpendicular to the center panel; folding the second partial side panel at the second folding interface to be substantially perpendicular to the center panel; folding the first tabbed side panel at the third folding interface to be substantially perpendicular to the center panel; folding the second tabbed side panel at the sixth folding interface to be substantially perpendicular to the center panel; folding the first tab at the fourth folding interface to be substantially perpendicular to the first tabbed side panel and substantially coplanar with the first partial side panel; folding the second tab at the fifth folding interface to be substantially perpendicular to the first tabbed side panel and substantially coplanar with the second partial side panel; folding the third tab at the seventh folding interface to be substantially perpendicular to the second tabbed side panel and substantially coplanar with the first partial side panel; folding the fourth tab at the eighth folding interface to be substantially perpendicular to the second tabbed side panel and substantially coplanar with the second partial side panel; applying tape to a first side interface that includes the first mating edge, the third mating edge, and the fifth mating edge, the taping effective to cause the first partial side panel, the first tab, and the third tab to remain coplanar; applying tape to a second side interface that includes the second mating edge, the fourth mating edge, and the sixth mating edge, the taping effective to cause the second partial side panel, the second tab, and the fourth tab to remain coplanar; applying glue to a wrapper configured to conform to an exterior surface of the folded planar paperboard structure; and attaching the wrapper to the exterior surface of the folded planar paperboard structure.

Example 19: The method of example 18, wherein the planar paperboard structure is manufactured from corrugated fiberboard.

Example 20: The method of example 18, wherein folding the planar paperboard structure into the rigid box, taping both sides of the first side interface, taping both sides of the second side interface, applying glue to the wrapper, and attaching the wrapper to the exterior surface of the folded planar paperboard structure are performed by automated box-assembly equipment.

Conclusion

Although aspects of an assembly structure for corrugated packaging have been described in language specific to features, techniques, and/or methods, the subject of the appended claims is not necessarily limited to the specific features, techniques, or methods described. Rather, the specific features, techniques, and methods are disclosed as example implementations of the assembly structure for corrugated packaging, and other equivalent features and methods are intended to be within the scope of the appended claims. Further, various different aspects are described, and it is to be appreciated that each described aspect can be implemented independently or in connection with one or more other described aspects. 

What is claimed is:
 1. A planar paperboard structure, comprising: a center panel; a first partial side panel extending from a first side of the center panel and including: a first folding interface between the first partial side panel and the first side of the center panel, the first partial side panel configured to fold at the first folding interface to be substantially perpendicular to the center panel; and a first mating edge opposite the first folding interface; a second partial side panel extending from a second side of the center panel that is opposite the first side of the center panel and including: a second folding interface between the second partial side panel and the second side of the center panel, the second partial side panel configured to fold at the second folding interface to be substantially perpendicular to the center panel; and a second mating edge opposite the second folding interface; a first tabbed side panel extending from a third side of the center panel, the first tabbed side panel including: a third folding interface between the first tabbed side panel and the third side of the center panel, the first tabbed side panel configured to fold at the third folding interface to be substantially perpendicular to the center panel; a first tab including: a third mating edge; and a fourth folding interface adjacent the first tabbed side panel, the first tab configured to fold at the fourth folding interface to be substantially perpendicular to the first tabbed side panel and to be substantially coplanar with the first partial side panel when the first partial panel is folded so that the first mating edge and the third mating edge are adjacent; and a second tab including: a fourth mating edge; and a fifth folding interface adjacent the first tabbed side panel, the second tab configured to fold at the fifth folding interface to be substantially perpendicular to the first tabbed side panel and to be substantially coplanar with the second partial side panel when the second partial panel is folded so that the second mating edge and the fourth mating edge are adjacent; a second tabbed side panel extending from a fourth side of the center panel, the fourth side of the center panel opposite the third side of the center panel, the second tabbed side panel including: a sixth folding interface between the second tabbed side panel and the fourth side of the center panel, the second tabbed side panel configured to fold at the sixth folding interface to be substantially perpendicular to the center panel; a third tab including: a fifth mating edge; and a seventh folding interface adjacent the second tabbed side panel, the third tab configured to fold at the seventh folding interface to be substantially perpendicular to the second tabbed side panel and to be substantially coplanar with the first partial side panel when the first partial panel is folded so that the first mating edge and the fifth mating edge are adjacent; and a fourth tab including: a sixth mating edge; and an eighth folding interface the second tabbed side panel, the fourth tab configured to fold at the eighth folding interface to be substantially perpendicular to the second tabbed side panel and to be substantially coplanar with the second partial side panel when the second partial panel is folded so that the second mating edge and the sixth mating edge are adjacent.
 2. The planar paperboard structure of claim 1, wherein the planar paperboard structure is manufactured from corrugated fiberboard.
 3. The planar paperboard structure of claim 2, wherein the corrugated fiberboard includes fluting, the fluting parallel to the first side of the center panel.
 4. The planar paperboard structure of claim 3, wherein a fluting grade of the corrugated fiberboard is: F-flute; E-flute; C-flute; or B-flute.
 5. The planar paperboard structure of claim 1, wherein: a distance the first partial side panel extends from the first folding interface is no more than approximately forty-five percent of a length of the first tabbed side panel measured from the third folding interface; and a distance the second partial side panel extends from the second folding interface is no more than approximately forty-five percent of a length of the first tabbed side panel measured from the third folding interface.
 6. The planar paperboard structure of claim 1, wherein: a distance the first partial side panel extends from the first folding interface is between approximately forty percent of a length of the first tabbed side panel measured from the third folding interface and approximately fifty percent of the length of the first tabbed side panel measured from the third folding interface; and a distance the second partial side panel extends from the second folding interface is between approximately forty percent of a length of the first tabbed side panel measured from the third folding interface and approximately fifty percent of the length of the first tabbed side panel measured from the third folding interface.
 7. The planar paperboard structure of claim 1, wherein: a distance the first partial side panel extends from the first folding interface is approximately forty-five percent of a length of the first tabbed side panel measured from the third folding interface; and a distance the second partial side panel extends from the second folding interface is approximately forty-five percent of a length of the first tabbed side panel measured from the third folding interface.
 8. The planar paperboard structure of claim 1, wherein the first partial side panel and the second partial side panel are trapezoidal.
 9. The planar paperboard structure of claim 1, wherein the first partial side panel and the second partial side panel are rectangular, semi-circular, or semi-ellipsoid.
 10. The planar paperboard structure of claim 1, wherein: the first mating edge includes a first arc; and the third mating edge and the fifth mating edge comprise a second arc, the second arc having a substantially same shape as the first arc.
 11. The planar paperboard structure of claim 1, wherein: the second mating edge includes a third arc; and the fourth mating edge and the sixth mating edge comprise a fourth arc, the fourth arc having a substantially same shape as the third arc.
 12. The planar paperboard structure of claim 1, wherein the center panel is rectangular.
 13. The planar paperboard structure of claim 1, wherein the center panel is: square; or ellipsoid.
 14. The planar paperboard structure of claim 1, wherein the planar paperboard structure includes an exterior perimeter that is die-cut.
 15. The planar paperboard structure of claim 1, wherein the first folding interface, the second folding interface, the third folding interface, the fourth folding interface, the fifth folding interface, the sixth folding interface, the seventh folding interface, and the eighth folding interface are creases or cut-creases.
 16. The planar paperboard structure of claim 1, wherein the planar paperboard structure is a single piece.
 17. The planar paperboard structure of claim 1, wherein: the first partial side panel is folded at the first folding interface to be substantially perpendicular to the center panel; the second partial side panel is folded at the second folding interface to be substantially perpendicular to the center panel; the first tabbed side panel is folded at the third folding interface to be substantially perpendicular to the center panel; the second tabbed side panel is folded at the sixth folding interface to be substantially perpendicular to the center panel; the first tab is folded at the fourth folding interface to be substantially perpendicular to the first tabbed side panel and substantially coplanar with the first partial side panel; the second tab is folded at the fifth folding interface to be substantially perpendicular to the first tabbed side panel and substantially coplanar with the second partial side panel; the third tab is folded at the seventh folding interface to be substantially perpendicular to the second tabbed side panel and substantially coplanar with the first partial side panel; the fourth tab is folded at the eighth folding interface to be substantially perpendicular to the second tabbed side panel and substantially coplanar with the second partial side panel; a first side interface that includes the first mating edge, the third mating edge, and the fifth mating edge, is taped on both sides, effective to cause the first partial side panel, the first tab, and the third tab to remain coplanar; a second side interface that includes the second mating edge, the fourth mating edge, and the sixth mating edge, is taped on both sides, effective to cause the second partial side panel, the second tab, and the fourth tab to remain coplanar; and further including another planar paperboard structure configured with an interior perimeter that is larger than an exterior perimeter of the planar paperboard structure, effective to enable the other planar paperboard structure to fit over the planar paperboard structure in a telescoping configuration wherein an interior surface of the other planar paperboard structure is adjacent an exterior surface of the planar paperboard structure.
 18. A method for forming a rigid box, comprising: folding a planar paperboard structure, the planar paperboard structure including: a center panel; a first partial side panel, the first partial side panel including a first folding interface and a first mating edge; a second partial side panel, the second partial side panel including a second folding interface and a second mating edge; a first tabbed side panel, the first tabbed side panel including a third folding interface, a first tab with a third mating edge and a fourth folding interface, and a second tab with a fourth mating edge and a fifth folding interface; a second tabbed side panel, the second tabbed side panel including a sixth folding interface, a third tab with a fifth mating edge and a seventh folding interface, and a fourth tab with a sixth mating edge and an eighth folding interface, the folding comprising: folding the first partial side panel at the first folding interface to be substantially perpendicular to the center panel; folding the second partial side panel at the second folding interface to be substantially perpendicular to the center panel; folding the first tabbed side panel at the third folding interface to be substantially perpendicular to the center panel; folding the second tabbed side panel at the sixth folding interface to be substantially perpendicular to the center panel; folding the first tab at the fourth folding interface to be substantially perpendicular to the first tabbed side panel and substantially coplanar with the first partial side panel; folding the second tab at the fifth folding interface to be substantially perpendicular to the first tabbed side panel and substantially coplanar with the second partial side panel; folding the third tab at the seventh folding interface to be substantially perpendicular to the second tabbed side panel and substantially coplanar with the first partial side panel; folding the fourth tab at the eighth folding interface to be substantially perpendicular to the second tabbed side panel and substantially coplanar with the second partial side panel; applying tape to a first side interface that includes the first mating edge, the third mating edge, and the fifth mating edge, the taping effective to cause the first partial side panel, the first tab, and the third tab to remain coplanar; applying tape to a second side interface that includes the second mating edge, the fourth mating edge, and the sixth mating edge, the taping effective to cause the second partial side panel, the second tab, and the fourth tab to remain coplanar; applying glue to a wrapper configured to conform to an exterior surface of the folded planar paperboard structure; and attaching the wrapper to the exterior surface of the folded planar paperboard structure.
 19. The method of claim 18, wherein the planar paperboard structure is manufactured from corrugated fiberboard.
 20. The method of claim 18, wherein folding the planar paperboard structure into the rigid box, taping both sides of the first side interface, taping both sides of the second side interface, applying glue to the wrapper, and attaching the wrapper to the exterior surface of the folded planar paperboard structure are performed by automated box-assembly equipment. 